Side airbag assemblies and methods of assembly

Abstract

A side airbag assembly is attachable to a frame of a seat of a vehicle. The side airbag assembly may include an inflatable airbag cushion in a packaged configuration. The inflatable airbag cushion may be inflated by an inflator in fluid communication with the inflatable airbag cushion to supply inflation gas to inflate the inflatable airbag cushion. The inflator may include an attachment stud to mount the airbag assembly to the side of a seat. The side airbag assembly may further include a wrapper configured to wrap around the inflator and the inflatable airbag cushion in the packaged configuration and a cap that is coupled to the wrapper. The cap is configured to enclose a first end of the inflatable airbag cushion in the packaged configuration.

The invention claimed is: 
     
       1. An airbag assembly in a packaged state comprising:
 an inflatable airbag cushion in a packaged configuration; 
 an inflator in fluid communication with the inflatable airbag cushion to supply inflation gas to inflate the inflatable airbag cushion, the inflator comprising an attachment stud to mount the airbag assembly to a side of a seat; 
 a wrapper configured to wrap around the inflator and the inflatable airbag cushion in the packaged configuration; and 
 a cap coupled to the wrapper, wherein the cap is configured to enclose a first end of the inflatable airbag cushion in the packaged configuration to increase stiffness at the first end. 
 
     
     
       2. The airbag assembly of  claim 1 , wherein the wrapper comprises a substantially rectangular shape to wrap around the inflatable airbag cushion in the packaged configuration, the rectangular shape including a first lateral end and a second lateral end, the first lateral end including a first aperture to secure the first lateral end at the attachment stud and the second lateral end including a second aperture to secure the second end at the attachment stud. 
     
     
       3. The airbag assembly of  claim 1 , wherein the inflator comprises a plurality of attachment studs that are spaced apart, and
 wherein the wrapper comprises a substantially rectangular shape, the wrapper comprises a first lateral end and a second lateral end each including one or more apertures of a plurality of apertures spaced apart, wherein each aperture of the one or more apertures is configured to receive one of the plurality of attachment studs of the inflator. 
 
     
     
       4. The airbag assembly of  claim 1 , wherein the cap comprises a predetermined amount of stiffness to prevent an upper portion of the airbag assembly from bending over when a foam pad for the seat slides into place on a frame of the seat. 
     
     
       5. The airbag assembly of  claim 1 , wherein the cap is formed to provide a degree of stiffness to counter forces on the cap, and thereby prevent an upper portion of the airbag assembly from bending over, when a foam pad for the seat slides into place on a frame of the seat. 
     
     
       6. The airbag assembly of  claim 1 , wherein the cap comprises a single sheet of material that is folded back upon itself along a fold forming a first panel and a second panel, wherein the first panel of the cap is coupled at a center portion of the wrapper and the second panel of the cap is coupled to the attachment stud of the inflator. 
     
     
       7. The airbag assembly of  claim 6 , wherein the second panel comprises an aperture that is configured to receive the attachment stud of the inflator. 
     
     
       8. The airbag assembly of  claim 6 , wherein the cap comprises a horizontal stitching seam that extends substantially from a first lateral edge of the cap to a second lateral edge of the cap. 
     
     
       9. The airbag assembly of  claim 8 , wherein the horizontal stitching seam is disposed a predetermined distance from the fold. 
     
     
       10. The airbag assembly of  claim 6 , wherein the cap comprise a pair of lateral stitching seams that extend along a first lateral edge of the cap and a second lateral edge of the cap, wherein the pair of lateral stitching seams couple the first panel to the second panel of the cap. 
     
     
       11. The airbag assembly of  claim 6 , wherein the second panel has a greater length than the first panel. 
     
     
       12. The airbag assembly of  claim 6 , wherein the first panel of the cap comprises a radius of curvature that is configured to guide foam for the seat when the foam is slid into place on a frame of the seat without bending an upper portion of the airbag assembly. 
     
     
       13. The airbag assembly of  claim 1 , wherein the wrapper and the cap are fabricated from a flexible material. 
     
     
       14. The airbag assembly of  claim 1 , wherein the inflator comprises two attachment studs that are vertically spaced apart. 
     
     
       15. A method of packaging a side airbag assembly comprising:
 obtaining an inflatable side airbag cushion with an inflator coupled to and in fluid communication with the inflatable side airbag cushion; 
 rolling the inflatable side airbag cushion; 
 wrapping the inflator and the rolled inflatable side airbag cushion with a wrapper; and 
 enclosing a first end of the rolled inflatable side airbag cushion with a cap, wherein the cap comprises a predetermined amount of stiffness to prevent an upper portion of the rolled inflatable side airbag cushion from bending over when foam for a seat is slid into place on a frame of the seat. 
 
     
     
       16. The method of  claim 15 , wherein the inflator comprises two attachment studs to mount the side airbag assembly to a side of a seat of a vehicle, wherein the two attachment studs are vertically spaced apart. 
     
     
       17. The method of  claim 16 , wherein the wrapper comprises a substantially rectangular shape, the wrapper comprises a first lateral end and a second lateral end with two apertures disposed in the first lateral end and the second lateral end with the apertures vertically spaced apart, wherein each aperture in each end is configured to receive one of the two attachment studs of the inflator. 
     
     
       18. The method of  claim 17 , wherein the cap comprises a single sheet of material that is folded back upon itself along a fold forming a first panel and a second panel, wherein the first panel of the cap is coupled to a center portion of the wrapper and the second panel of the cap comprises an aperture that is configured to receive one of the attachment studs of the inflator. 
     
     
       19. The method of  claim 15 , further comprising mounting the side airbag assembly to a side of a seat of a vehicle.